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BMW AG Motorcycle (R 850 C, R 1200 C). Manual - part 17

23.14

Dismantling/reassembling output shaft

Stripping down output shaft

Caution:

To avoid damaging the needle roller bearing at the
splines, open it out carefully at the joint line before
removing.

•

Using universal puller, BMW No. 00 7 500, pull
off deep-groove ball bearing (22) together with
1st gear wheel (20).

•

Remove spacing washer (21), shift gear wheel for
1st gear (20), needle roller bearing (19) and
spacing washer (18).

•

Remove sliding gearwheel (7).

•

Remove circlip (8), support washer (9), shift
gearwheel for 3rd gear (10) and needle roller
bearing (11).

•

Remove support washer (12), 4th gear shift
wheel (13), needle roller bearing (14) and support
washer (15).

•

Remove circlip (16) and sliding gearwheel for
5th gear (17).

•

Turn output shaft (6) and clamp into the vise with
soft jaws.

•

Using universal puller, BMW No. 00 7 500, pull
off deep-groove ball bearing (1) together with
shift gearwheel for 2nd gear (4).

•

Remove shim washer (2), needle roller bearing (3),
shift gearwheel for 2nd gear (4) and thrust wash-
er (5).

KR230100

00 7 500

KR230110

23.15

Assembling output shaft

Note:

Assembly starts at the shift gearwheel for 4th gear.
Before assembly, oil all running surfaces lightly with
gear oil.

•

Clamp the output shaft into the vise with soft
jaws and with the splines facing upwards.

•

Install circlip (16/arrow).

•

Install thrust washer (15).

•

Install needle roller bearing (14).

Caution:

To avoid damaging the needle roller bearing at the
splines, spread it carefully at the butt joint before in-
stalling.

•

Install shift wheel for 4th gear (13) with the pock-
ets facing circlip (16).

•

Install support washer (12) and needle roller (11).

•

Install shift wheel for 3rd gear (10) with pockets
facing away from the 4th gear shift wheel (13).

•

Install support washer (9) and circlip (8).

•

After installing the 3rd and 4th shift gearwheels,
measure endplay (

23.16).

•

Install sliding gear (7) with the recess for the se-
lector fork facing the shift gearwheel for 3rd gear
(10).

•

Install support washer (18) and needle roller
bearing (19).

•

Install the shift gearwheel for 1st gear (20) with
the pockets facing sliding gearwheel (7).

•

Install spacing washer (21) and deep-groove ball
bearing (22).

•

After installing, check endplay at the shift gear-
wheel for 1st gear (

23.16).

KR230120

5th gear

2nd gear

4th gear

3rd gear

1st gear

KR230130

23.16

•

Transfer output shaft (6) to new position in vise.

•

Install shift wheel for 5th gear (17) with the recess
for the selector fork facing the 2nd gear shift
wheel (3).

•

Install support washer (5) and needle roller bear-
ing (4).

•

Install the shift wheel for 2nd gear (3) with the
dogs facing the 5th gear shift wheel (17).

•

Check/adjust the fully-compressed length
(

23.19).

•

Install spacing washer (2) of the determined
thickness, and press on deep-groove ball bear-
ing (1).

•

Check endplay at 2nd (

23.16).

Checking endplay

•

Attach dial gauge, BMW No. 00 2 510, to dial
gauge stand.

•

Apply the dial gauge to the edge of the gear-
wheel and check endplay.

Caution:

If endplay is beyond the permitted tolerances, this
indicates either an assembly error or wear in the
needle roller bearings, the support or spacing wash-
ers or the shift gear.
Check for wear and renew the affected parts.

Endplay values:
Endplay, 1st gear .. 0.1…0.33 mm (0.004…0.013 in)
Endplay,
2nd gear ............... 0.1…0.33 mm (0.004…0.013 in)
Endplay, 3rd/4th gear
(total play).............. 0.1…0.67 mm (0.004…0.026 in)

KR230140

40 50 60

100

KR230150

00 2 510

23.17

Checking/adjusting fully compressed
length of gearbox shafts and selector
drum

Checking/adjusting fully-compressed length of
intermediate shaft

Caution:

To adjust and check the fully-compressed length,
measure deviation from zero as described below
and adjust with a shim washer.
Before each measurement, even if the shaft is not
being installed, make sure that the deep-groove ball
bearing is fully compressed.

•

Pull off the input-side deep-groove ball bearing
with universal puller, BMW No. 00 7 500.

•

Take off the spacing washer.

•

Insert zero gauge, BMW No. 23 4 763, into
measuring stand, BMW No. 23 4 761.

•

Secure dial gauge, BMW No. 23 4 762, in rear
mounting hole on measuring stand,
BMW No. 23 4 761, and set to 0.2 mm (0.008 in)
preload.

•

Using the dial gauge, zero to dimension “A” of
the zero gauge, BMW No. 23 4 763.

•

Remove the zero gauge from the measuring fix-
ture.

•

Place measuring disc, BMW No. 23 4 765, on
the intermediate shaft.

•

Place deep-groove ball bearing on measuring
disc.

•

Insert intermediate shaft in measuring stand.

•

Using dial gauge, measure deviation from zero of
dimension “B” at inner bearing race.

The deviation from zero is equivalent to the thick-
ness “C” of spacing washer (1).

•

Place a spacing washer (1) of the thickness just
determined on the inner bearing race and check
deviation from zero.

A = B + C

Caution:

The maximum permitted deviation from zero must
not be exceeded.

•

Remove the intermediate shaft from the measur-
ing fixture.

•

Take off spacing washer, the deep-groove ball
bearing and the measuring disc.

•

Place a spacing washer (1) of the determined
thickness on the intermediate shaft and press on
the deep-groove ball bearing.

Adjusting dimensions for intermediate shaft:
Maximum deviation
from zero ......... -0.05 mm (0.002 in) … 0.00 mm/in
Fully-compressed
length......... 198.95…199.00 mm (7.833…7.835 in)

C230051

23 4 763

23 4 761

23 4 762

23 4 765

0.2 (0.004 in)

23.18

Checking/adjusting fully-compressed length of
output shaft

Caution:

To check and adjust the fully-compressed length,
measure deviation from zero as described below
and adjust with a shim washer.
Before each measuring step, even if the shaft is not
to be installed, make sure that the deep-groove ball
bearing is fully compressed.

•

Pull off output-side deep-groove ball bearing
with universal puller, BMW No. 00 7 500.

•

Take off the spacing washer.

•

Insert zero gauge, BMW No. 23 4 763, in to
measuring stand, BMW No. 23 4 761.

•

Secure dial gauge, BMW No. 23 4 762, in rear
mounting hole on measuring stand,
BMW No. 23 4 761, and set to 0.2 mm
(0.008 in) preload.

•

Using the dial gauge, zero to dimension “A” of
the zero gauge, BMW No. 23 4 763.

•

Remove the zero gauge from the measuring fix-
ture.

•

Place the measuring disc, BMW No. 23 4 766,
on the output shaft.

•

Place the deep-groove ball bearing on the meas-
uring disc.

•

Insert the output shaft into the measuring stand.

•

Using the dial gauge, measure the deviation from
zero of dimension “B” at the inner bearing race.

The deviation from zero represents thickness “C” of
spacing washer (1).

•

Place spacing washer (1) of the thickness just
determined on the inner bearing race, and check
deviation from zero.

A = B + C

Caution:

The maximum deviation from zero must not be ex-
ceeded.

•

Remove output shaft from measuring fixture.

•

Take off spacing washer, deep-groove ball bear-
ing and measuring disc.

•

Place a spacing washer (1) of the determined
thickness on the output shaft and press on the
deep-groove ball bearing.

Output shaft adjusting dimensions:
Maximum deviation
from zero ......... -0.05 mm (0.002 in) … 0.00 mm/in
Fully-compressed
length......... 192.95…193.00 mm (7.596…7.598 in)

KR230300

23 4 763

23 4 761

23 4 762

23 4 766

0.2

23.19

Checking/adjusting fully-compressed length of
input shaft

Caution:

To adjust and check the fully-compressed length,
deviation from zero must be measured as described
below, and adjusted by means of a shim washer.
Make sure before each measuring step, even if the
shaft is not being installed, that the deep-groove ball
bearing is fully compressed.

•

Pull off output-side deep-groove ball bearing
with universal puller, BMW No. 00 7 500.

•

Take off the spacing washer.

•

Insert zero gauge, BMW No. 23 4 763, into
measuring stand, BMW No. 23 4 761.

•

Secure dial gauge, BMW No. 23 4 762, in front
mounting hole on measuring stand,
BMW No. 23 4 761, and set to 0.2 mm (0.008 in)
preload.

•

Using dial gauge, zero to dimension “A” of the
zero gauge, BMW No. 23 4 763.

•

Remove the zero gauge from the measuring fix-
ture.

•

Mount measuring disc, BMW No. 23 4 764, on
the input shaft.

•

Place the deep-groove ball bearing on the meas-
uring disc.

•

Insert input shaft with adapter disc,
BMW No. 23 4 767, in measuring stand.

•

Using the dial gauge, measure deviation from
zero to dimension “B” at the inner bearing race.

The deviation from zero represents the thickness
“C” of spacing washer (1).

•

Place a spacing washer (1) of the determined
thickness on the inner bearing race and check
the deviation from zero.

A = B + C

Caution:

The maximum deviation from zero must not be ex-
ceeded.

•

Take the input shaft out of the measuring fixture.

•

Take off the adapter disc, spacing washer, deep-
groove ball bearing and measuring disc.

•

Place a spacing washer (1) of the determined
thickness in position and press the deep-groove
ball bearing on to the input shaft.

Adjusting dimensions for input shaft:
Maximum deviation
from zero ......... -0.05 mm (0.002 in) … 0.00 mm/in
Fully-compressed
length......... 138.55…138.60 mm (5.455…5.457 in)

23 4 762

KR230290

23 4 767

23 4 764

0.2

23 4 763

23 4 761

23.20

Checking/adjusting fully-compressed length of
selector drum

•

Place spacing washer and both thrust washers
on the selector drum.

•

Using depth gauge, determine fully-compressed
length “A”.

•

If necessary, adjust fully-compressed length “A”
with a shim washer (arrow).

Fully-compressed length:
Selector
drum .......... 111.80…111.90 mm (4.402…4.406 in)

KR230190

23.21

Shimming selector shaft

Caution:

If the housing or the complete selector shaft is re-
newed, the selector shaft must be measured and
shimmed again.

•

Measure dimension “A” from shouldered bush-
ing to cover joint face.

•

Measure dimension “B” from shouldered bush-
ing to housing joint face.

•

Measure dimension “C” from the shoulder on the
selector shaft to the back of the sleeve.

•

Determine endplay as follows:

Dimensions “A” + “B” = “D”
Dimensions “D” - “C” = “E”
Dimensions “E” - thickness of spacing washer =
endplay.

Endplay:
Selector shaft ......... 0.1…0.3 mm (0.004…0.012 in)

KR230200

KR230210

KR230220

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